The right choice for root protection work

Back shielding and root protection ensure perfect weld seams

Profit from forming

For more than 40 years, root protection and forming have proven their value in welding technology. They permit an increase in weld seam quality and contribute to a reduction of follow-up costs. The focus here is on reworking, pickling costs, the associated transport costs and the not inconsiderable loss of time. With correct forming, weld seams and roots can be produced which need no reworking. Forming and root protection Root protection is the shielding of the weld root and the heat affected zone with specially formulated gases, while simultaneously displacing atmospheric oxygen (DVS Data Sheet 0937). When applied to pipes and tanks, it is known as forming. This technique is used for the welding of gas sensitive materials such as high alloyed CrNi steels, for example, to ensure the corrosion resistance of the materials. Without forming, the weld root and the heat affected zone are oxidised by the oxygen in the atmosphere. Forming gases are even occasionally used for the welding of unalloyed steels in order to improve the root quality. The correct welding of gas sensitive materials, such as titanium, zirconium, molybdenum or magnesium, for example, is actually impossible without forming.
Laminar and turbulent flow

Laminar flow instead of turbulence In order to ensure the high quality and economy of the work, a few basic rules must be observed. One of the most important concerns the feed of the shield gas to the weld seam region. This should never be uncontrolled. In an optimum shield gas feed, the flow is laminar. If the flow is turbulent, the eddies result in mixing of the forming gas and the atmosphere. A laminar flow is generated with the help of a diffusor, usually comprising pipes, sheets or mouldings of sinter material. The sinter metal distributes the gas feed over a large area, from which the forming gas is emitted in laminar form. Forming techniques are divided, according to the physical properties of the forming gases, into: Forming with gases lighter than air Forming with gases heavier than air Forming with gases of the same weight as air Forming with gases which are lighter or heavier than air The distinguishing factor is the difference in weight between the forming gas and air. When gas mixtures with a weight greater than air are used, the vessel is filled from the bottom up and has a vent at the top for escape of the atmospheric air displaced. In the case of gas mixtures with a lower weight than air, this mechanism is reversed.

Root without root protection

Root with root protection

Forming gas (l.) lighter than air and (r.) heavier than air. Red marking: Weld seam zone

The choice of technique can be decided by the forming gases available locally or, in the case of large construction components, for example because of the position of the weld area in the component, they may be deliberately applied. Forming of pipes In the forming of pipes, problems may arise due to mixing if the difference in weight between the forming gas and air is too great. In order to prevent this mixing, gas mixtures with the same weight as air can be used. These are argon/nitrogen/hydrogen mixtures with a variable hydrogen content.

1. The material to be formed gas sensitivity? 2. The forming task upper or lower component area? 3. The shape of the component sheet, tank or pipe? Incompatibilities may occur between materials and gases. The constituents of the forming gases, for example, may damage the material through the formation of nitrides or oxides or through hydrogen cracks. Particular attention must be paid to this when selecting the forming gases. The table gives an overview of recommended forming gases. The shape of the component may also have an influence on the choice of gas. In the case of pipes and tanks with complicated geometries, forming with gases lighter or heavier than air is often accompanied by the common problem of irregular forming results. Here, a gas mixture with the same weight as air can be used for even filling of the tank or pipe. Customerspecific argon, nitrogen and hydrogen mixtures with varying hydrogen content permit quick and reliable forming.

Forming gas

Flow in pipes

Root protection Argon/ hydrogen mixtures

Materials Austenitic Cr-Ni steels, Ni and Ni-based materials

The right hose material Another important component is the shield gas hose itself. Here, the hose material is crucial. Generally available PVC hoses, originally intended for the transport of compressed air, are not suitable for this purpose. The hose material is capable of absorbing moisture from the atmosphere and passing it on to the dry forming gas. Hoses manufactured in accordance with DIN EN 559 and marked accordingly usually meet the requirements and can be obtained from any wellstocked welding accessory dealer. Savings made at this stage may turn out to be very expensive! Which gas for which application? The gas mixtures in question are based on argon or nitrogen. To reduce the residual oxygen, hydrogen is added to the gases. In addition to their weight relative to air, other criteria may also be applied for selection of suitable gases:

Steels, with the exception of Nitrogen/hydro high-strength, fine-grained gen mixtures construction steels, austenitic Cr-Ni steels Austenitic Cr-Ni steels, austenitic-ferritic steels (duplex), gas sensitive materials (titanium, zirconium, molybdenum), hydrogen sensitive materials (highstrength, fine-grained construction steels, copper and copper alloys, aluminium and aluminium alloys and other NF metals), ferritic Cr steels Austenitic Cr-Ni steels, austenitic-ferritic steels (duplex)

Argon

Nitrogen

Choice of metal and forming gases

Flammable range The final consideration is extremely important: "How much hydrogen do I need for my forming process?" According to their hydrogen content, forming gases may be combustible in the atmosphere. These must be flared off as they leave the component being formed. The ignition limit is 4% H2 and the gases must be flared off at 10% H2 (DVS Data Sheet 0937). A distinction is made between spontaneously and non-spontaneously igniting forming gases. In the case of non-spontaneously igniting mixtures, the use of a pilot flame is necessary. A risk in the use of flammable forming gases is that of deflagration. This exists if a flammable mixture of forming gas and air is still present at the start of the welding work. The forming gas/air mixture in the tank varies its composition continuously during the forming, passing through a flammable range.

Residual oxygen When gassing a tank or a pipe with forming gas, in spite of observing a precise working procedure, mixing with the atmosphere to a greater or lesser degree is inevitable. During welding, the resulting residual oxygen content leads to oxidation of the surface, manifesting itself as annealing colours. As the forming process progresses, the residual oxygen content in the tank is reduced. Depending on the material, a sufficiently low residual oxygen content must be set before the welding work commences. As a rule, this is approx. 20-50 ppm. An indication of the residual oxygen content can be obtained with a suitable measuring instrument. In the case of series components with low manufacturing costs, the optimum purge time can also be determined empirically by trial and error.

H2 content in %

Flammability limit/ Minimum content O2

0 ppm
Flammability limit/ Minimum content H2

10 ppm

18 ppm

28 ppm

O2 Air N2H2

49 ppm

73 ppm

97 ppm

150 ppm

The graph shows the flammable ranges of different N2/H2 gas mixtures.

Influence of the residual oxygen content on the forming result

Determining prepurging times When the correct procedure is followed, the prepurging times for the different components are dependent only on the required residual oxygen content. That means, the more sensitive the material, the longer the prepurging time. In the case of sheet metal and irregular tanks, the residual oxygen content can be measured or the purging time can be determined empirically. For the forming of pipes, there is a graphic aid (DVS Data Sheet 0937) for determination of an adequate purging time.Dependent on the pipe diameter, the purging time per metre of pipe can be determined. Aids for root protection and forming For root protection or forming, the affected zone should, if possible, be spatially demarcated. Numerous aids for this purpose are available from dealers.

Root protection for sheet metal welding In the case of sheet metal welding, the root zone is often accessible, so that a forming device can be attached. This applies both for butt joints and for T and corner joints. The device must completely cover the root and the heat affected zone. In principle, a distinction must be made between butt and T joints. On completion of the welding work, the component temperature must be measured and the cover only removed after it has cooled sufficiently.

Photo: Jankus

Shield gas angle profile for corner seams

Forming of pipes and tanks Compared with root protection for sheet metal welding, the forming of pipes and tanks is more complicated. The roots of the joints are often difficult to get at. Adequate covering of the root zone with forming gas can usually only be achieved by using special forming devices or, in extreme cases, by completely filling the pipe.

Sinter metal shield gas finger for the forming of pipes

Photo: Jankus

Shield gas cylinder for the forming of pipes

Advice, Delivery, Service

Technical centres

Krefeld

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Budapest

Shanghai

Technical centres sources for innovation For the development of new technologies in the field of welding and cutting, Messer operates technical centres in Germany, Switzerland, Hungary and China. These facilities provide ideal conditions for innovative projects as well as customer presentations and training courses. Portfolio of gases comprehensive and clear Messer offers a spectrum of gases that extends well beyond the standard fare: it ranges from just the right gas for each application, and clear, application-oriented product designations to the continuous introduction of new gas mixtures designed to address current trends. Specialised on-site consulting right where you need it Specifically in the context of your particular application, we can show you how to optimise the efficiency and quality of your processes. Along with process development, we support you with troubleshooting and process development. Cost analyses fast and efficient We will be glad to analyze your existing processes, develop optimisation proposals, support process modifications and compare the results with the original conditions because your success is also our success.

Training courses always up to date For the optimal handling of our gases, we can train you on processes and how to use them. Our training courses illustrate the use of various shielding gases for welding and explain how to handle them safely. This also includes the storage of the gases and the safe transport of small quantities. Information and training materials for your plant are also part of the service, of course. You can also download this brochure and many others from the Internet as a PDF file: www.messergroup.com

Messer Group GmbH Gahlingspfad 31 47803 Krefeld Tel. +49 2151 7811-0 Fax +49 2151 7811-503 welding-technology@messergroup.com www.messergroup.com